ironman 230 and m-25 gun - tractor supply companyom-235281 page 1 section 1 − safety precautions -...

www.HobartWelders.com

OM-235281E 2017−03

Processes

Gas Metal Arc (MIG) Welding

Flux Cored Arc (FCAW)Welding

Description

Arc Welding Power Source and WireFeeder

IronMan 230And M-25 Gun

™

File: MIG (GMAW)

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . .1-4. California Proposition 65 Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Symboles utilisés 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 72-4. Proposition californienne 65 Avertissements 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6. Informations relatives aux CEM 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Additional Safety Symbols And Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2. Miscellaneous Symbols And Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SPECIFICATIONS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Serial Number And Rating Label Location 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Unit Specifications 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Welding Power Source Duty Cycle And Overheating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. Environmental Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Volt-Ampere Curves 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Selecting A Location 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Installing Welding Gun 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Connecting Weld Output Cables 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Installing Work Clamp 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Setting Gun Polarity For Wire Type 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6. Installing 2 lb Wire Spool And Adjusting Hub Tension 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7. Installing 10 lb Wire Spool And Adjusting Hub Tension 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8. Installing 33 lb Wire Spool And Adjusting Hub Tension 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9. Installing Gas Supply 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10. Positioning Jumper Links 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11. Electrical Service Guide 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12. Connecting 1-Phase Input Power 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13. Threading Welding Wire 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14. Installing Optional DP 3545 Spool Gun To Welding Power Source 21. . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − OPERATION 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Controls 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Weld Parameters 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Routine Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Supplementary Protectors 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Replacing Drive Roll And Wire Inlet Guide 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4. Removing Knob From Front Panel 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5. Aligning Drive Rolls and Wire Guide 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6. Replacing Gun Contact Tip 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7. Installing Cable Hangers 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing 27. . .7-9. Welding Troubleshooting Table 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10. Wire Drive/Gun Troubleshooting Table 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − GMAW WELDING (MIG) GUIDELINES 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 − ELECTRICAL DIAGRAM 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 10 − ACCESSORIES/CONSUMABLES 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .COMPLETE PARTS LIST − Available at www.HobartWelders.comWARRANTY

Hobart is registered tothe ISO 9001 QualitySystem Standard.

OM-235281 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom 2015−09

7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.

Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or ex-plained in the text.

NOTICE − Indicates statements not related to personal injury.

� Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-bols and related instructions below for necessary actions to avoid thehazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1-5. Read andfollow all Safety Standards.

Only qualified persons should install, operate, maintain, andrepair this unit.

During operation, keep everybody, especially children, away.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automaticwire welding, the wire, wire reel, drive roll housing,and all metal parts touching the welding wire areelectrically live. Incorrectly installed or improperlygrounded equipment is a hazard.

� Do not touch live electrical parts.

ELECTRIC SHOCK can kill.

� Wear dry, hole-free insulating gloves and body protection.� Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the workor ground.

� Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

� Use AC output ONLY if required for the welding process.� If AC output is required, use remote output control if present on

unit.� Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoid-able or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic DC constant voltage (wire) welder, 2) a DC manual(stick) welder, or 3) an AC welder with reduced open-circuit volt-age. In most situations, use of a DC, constant voltage wire welderis recommended. And, do not work alone!

� Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

� Properly install, ground, and operate this equipment according toits Owner’s Manual and national, state, and local codes.

� Always verify the supply ground − check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

� When making input connections, attach proper grounding conduc-tor first − double-check connections.

� Keep cords dry, free of oil and grease, and protected from hot metaland sparks.

� Frequently inspect input power cord and ground conductor fordamage or bare wiring – replace immediately if damaged – barewiring can kill.

� Turn off all equipment when not in use.� Do not use worn, damaged, undersized, or repaired cables.� Do not drape cables over your body.� If earth grounding of the workpiece is required, ground it directly

with a separate cable.� Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.� Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will bepresent.

� Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

� Wear a safety harness if working above floor level.� Keep all panels and covers securely in place.� Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

� Insulate work clamp when not connected to workpiece to preventcontact with any metal object.

� Do not connect more than one electrode or work cable to anysingle weld output terminal. Disconnect cable for process not inuse.

� Use GFCI protection when operating auxiliary equipment in dampor wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld-ing power sources AFTER removal of input power.� Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

HOT PARTS can burn.

� Do not touch hot parts bare handed.� Allow cooling period before working on

equipment.

� To handle hot parts, use proper tools and/or wear heavy, insu-lated welding gloves and clothing to prevent burns.

OM-235281 Page 2

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.

� Keep your head out of the fumes. Do not breathe the fumes.� If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases. The recommended wayto determine adequate ventilation is to sample for the compositionand quantity of fumes and gases to which personnel are exposed.

� If ventilation is poor, wear an approved air-supplied respirator.� Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,consumables, coolants, degreasers, fluxes, and metals.

� Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

� Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

� Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

� Wear an approved welding helmet fitted with a proper shade offilter lenses to protect your face and eyes from arc rays andsparks when welding or watching (see ANSI Z49.1 and Z87.1listed in Safety Standards).

� Wear approved safety glasses with side shields under yourhelmet.

� Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

� Wear body protection made from durable, flame−resistant mate-rial (leather, heavy cotton, wool). Body protection includesoil-free clothing such as leather gloves, heavy shirt, cufflesstrousers, high shoes, and a cap.

ARC RAYS can burn eyes and skin.

Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

WELDING can cause fire or explosion.

� Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.

� Do not weld where flying sparks can strike flammable material.� Protect yourself and others from flying sparks and hot metal.� Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.� Watch for fire, and keep a fire extinguisher nearby.� Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.� Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they areproperly prepared according to AWS F4.1 and AWS A6.0 (seeSafety Standards).

� Do not weld where the atmosphere can contain flammable dust,gas, or liquid vapors (such as gasoline).

� Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock, sparks, and firehazards.

� Do not use welder to thaw frozen pipes.

� Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.

� Wear body protection made from durable, flame−resistant material(leather, heavy cotton, wool). Body protection includes oil-freeclothing such as leather gloves, heavy shirt, cuffless trousers, highshoes, and a cap.

� Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

� After completion of work, inspect area to ensure it is free of sparks,glowing embers, and flames.

� Use only correct fuses or circuit breakers. Do not oversize or by-pass them.

� Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51Bfor hot work and have a fire watcher and extinguisher nearby.

� Read and understand the Safety Data Sheets (SDSs) and themanufacturer’s instructions for adhesives, coatings, cleaners,consumables, coolants, degreasers, fluxes, and metals.

FLYING METAL or DIRT can injure eyes.

� Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.

� Wear approved safety glasses with sideshields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

� Shut off compressed gas supply when not in use.� Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF)can affect Implanted Medical Devices.

� Wearers of Pacemakers and other ImplantedMedical Devices should keep away.

� Implanted Medical Device wearers should consult their doctorand the device manufacturer before going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heatingoperations.

Noise from some processes or equipment candamage hearing.

� Wear approved ear protection if noise lev-el is high.

NOISE can damage hearing.

Compressed gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

� Protect compressed gas cylinders from excessive heat, mechani-cal shocks, physical damage, slag, open flames, sparks, and arcs.

� Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

� Keep cylinders away from any welding or other electrical circuits.� Never drape a welding torch over a gas cylinder.� Never allow a welding electrode to touch any cylinder.� Never weld on a pressurized cylinder − explosion will result.� Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain themand associated parts in good condition.

� Turn face away from valve outlet when opening cylinder valve. Donot stand in front of or behind the regulator when opening the valve.

� Keep protective cap in place over valve except when cylinder is inuse or connected for use.

� Use the right equipment, correct procedures, and sufficient num-ber of persons to lift and move cylinders.

� Read and follow instructions on compressed gas cylinders,associated equipment, and Compressed Gas Association (CGA)publication P-1 listed in Safety Standards.

OM-235281 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

� Do not install or place unit on, over, or nearcombustible surfaces.

� Do not install unit near flammables.

� Do not overload building wiring − be sure power supply system isproperly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

� Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

� Use equipment of adequate capacity to lift andsupport unit.

� If using lift forks to move unit, be sure forks are long enough toextend beyond opposite side of unit.

� Keep equipment (cables and cords) away from moving vehicleswhen working from an aerial location.

� Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94−110) when manu-ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

� Allow cooling period; follow rated duty cycle.� Reduce current or reduce duty cycle before

starting to weld again.� Do not block or filter airflow to unit.

FLYING SPARKS can injure.

� Wear a face shield to protect eyes and face.� Shape tungsten electrode only on grinder with

proper guards in a safe location wearing properface, hand, and body protection.

� Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

� Put on grounded wrist strap BEFORE handlingboards or parts.

� Use proper static-proof bags and boxes tostore, move, or ship PC boards.

MOVING PARTS can injure.

� Keep away from moving parts.� Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

� Do not press gun trigger until instructed to doso.

� Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

BATTERY EXPLOSION can injure.

� Do not use welder to charge batteries or jumpstart vehicles unless it has a battery chargingfeature designed for this purpose.

MOVING PARTS can injure.

� Keep away from moving parts such as fans.� Keep all doors, panels, covers, and guards

closed and securely in place.

� Have only qualified persons remove doors, panels, covers, orguards for maintenance and troubleshooting as necessary.

� Reinstall doors, panels, covers, or guards when maintenance isfinished and before reconnecting input power.

READ INSTRUCTIONS.

� Read and follow all labels and the Owner’sManual carefully before installing, operating, orservicing unit. Read the safety information atthe beginning of the manual and in eachsection.

� Use only genuine replacement parts from the manufacturer.

� Perform installation, maintenance, and service according to theOwner’s Manuals, industry standards, and national, state, andlocal codes.

H.F. RADIATION can cause interference.

� High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

� Have only qualified persons familiar withelectronic equipment perform this installation.

� The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

� If notified by the FCC about interference, stop using theequipment at once.

� Have the installation regularly checked and maintained.

� Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

� Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

� Be sure all equipment in the welding area iselectromagnetically compatible.

� To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

� Locate welding operation 100 meters from any sensitive elec-tronic equipment.

� Be sure this welding machine is installed and groundedaccording to this manual.

� If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

OM-235281 Page 4

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Section 25249.5 et seq.)

This product contains chemicals, including lead, known tothe state of California to cause cancer, birth defects, or otherreproductive harm. Wash hands after use.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,is available as a free download from the American Welding Society athttp://www.aws.org or purchased from Global Engineering Documents(phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Weldingand Cutting, American Welding Society Standard AWS F4.1, from Glob-al Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com-bustibles, American Welding Society Standard AWS A6.0, from GlobalEngineering Documents (phone: 1-877-413-5184,website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 14501 George Carter Way, Suite103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga-net.com).

Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, from Canadian Standards Association, Standards Sales, 5060Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS(phone: 800-463-6727, website: www.csagroup.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, from American National Standards Institute,25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-site: www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, from National Fire Protection Association,Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website:www.osha.gov).Applications Manual for the Revised NIOSH Lifting Equation, The Na-tional Institute for Occupational Safety and Health (NIOSH), 1600Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electricand magnetic fields (EMF). The current from arc welding (and allied pro-cesses including spot welding, gouging, plasma arc cutting, andinduction heating operations) creates an EMF field around the weldingcircuit. EMF fields can interfere with some medical implants, e.g. pace-makers. Protective measures for persons wearing medical implantshave to be taken. For example, restrict access for passers−by or con-duct individual risk assessment for welders. All welders should use thefollowing procedures in order to minimize exposure to EMF fields fromthe welding circuit:

1. Keep cables close together by twisting or taping them, or using acable cover.

2. Do not place your body between welding cables. Arrange cablesto one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in thewelding circuit as possible.

5. Connect work clamp to workpiece as close to the weld aspossible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wirefeeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and thedevice manufacturer before performing or going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heating operations.If cleared by your doctor, then following the above procedures is recom-mended.

OM-235281 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONfre_som_2015−09

7

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relativesaux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si onl’évite pas peut donner la mort ou des blessures graves.Les dangers possibles sont montrés par les symbolesjoints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite paspeut donner la mort ou des blessures graves. Les dan-gers possibles sont montrés par les symboles joints ousont expliqués dans le texte.

AVIS − Indique des déclarations pas en relation avec des blessurespersonnelles.

� Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGERDE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECESCHAUDES. Consulter les symboles et les instructions ci-dessous yafférant pour les actions nécessaires afin d’éviter le danger.

2-2. Dangers relatifs au soudage à l’arc

Les symboles représentés ci-dessous sont utilisés dans ce ma-nuel pour attirer l’attention et identifier les dangers possibles. Enprésence de l’un de ces symboles, prendre garde et suivre lesinstructions afférentes pour éviter tout risque. Les instructionsen matière de sécurité indiquées ci-dessous ne constituentqu’un sommaire des instructions de sécurité plus complètesfournies dans les normes de sécurité énumérées dans la Sec-tion 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonc-tionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes lespersonnes, notamment les enfants de l’appareil.

Le contact d’organes électriques sous tension peutprovoquer des accidents mortels ou des brûluresgraves. Le circuit de l’électrode et de la pièce est soustension lorsque le courant est délivré à la sortie. Lecircuit d’alimentation et les circuits internes de lamachine sont également sous tension lorsque l’alimen-tation est sur Marche. Dans le mode de soudage avecdu fil, le fil, le dérouleur, le bloc de commande durouleau et toutes les parties métalliques en contactavec le fil sont sous tension électrique. Un équipementinstallé ou mis à la terre de manière incorrecte ouimpropre constitue un danger.

UNE DÉCHARGE ÉLECTRIQUE peutentraîner la mort.

� Ne pas toucher aux pièces électriques sous tension.� Porter des gants isolants et des vêtements de protection secs et

sans trous.� S’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec lapièce à couper ou le sol.

� Ne pas se servir de source électrique à courant électrique dans leszones humides, dans les endroits confinés ou là où on risque detomber.

� Se servir d’une source électrique à courant électrique UNIQUE-MENT si le procédé de soudage le demande.

� Si l’utilisation d’une source électrique à courant électrique s’avèrenécessaire, se servir de la fonction de télécommande si l’appareilen est équipé.

� D’autres consignes de sécurité sont nécessaires dans les condi-tions suivantes : risques électriques dans un environnementhumide ou si l’on porte des vêtements mouillés ; sur des structuresmétalliques telles que sols, grilles ou échafaudages ; en positioncoincée comme assise, à genoux ou couchée ; ou s’il y a un risqueélevé de contact inévitable ou accidentel avec la pièce à souder oule sol. Dans ces conditions, utiliser les équipements suivants,dans l’ordre indiqué : 1) un poste à souder DC à tension constante(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste àsouder AC à tension à vide réduite. Dans la plupart des situations,l’utilisation d’un poste à souder DC à fil à tension constante est re-commandée. En outre, ne pas travailler seul !

� Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-stallation, à la réparation ou à l’entretien de l’appareil. Déverrouillerl’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-mes de sécurité).

� Installez, mettez à la terre et utilisez correctement cet équipementconformément à son Manuel d’Utilisation et aux réglementationsnationales, gouvernementales et locales.

� Toujours vérifier la terre du cordon d’alimentation. Vérifier ets’assurer que le fil de terre du cordon d’alimentation est bienraccordé à la borne de terre du sectionneur ou que la fiche ducordon est raccordée à une prise correctement mise à la terre.

� En effectuant les raccordements d’entrée, fixer d’abord le conduc-teur de mise à la terre approprié et contre-vérifier les connexions.

� Les câbles doivent être exempts d’humidité, d’huile et de graisse;protégez−les contre les étincelles et les pièces métalliqueschaudes.

� Vérifier fréquemment le cordon d’alimentation et le conducteur demise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî-ner la mort.

� L’équipement doit être hors tension lorsqu’il n’est pas utilisé.� Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.� Ne pas enrouler les câbles autour du corps.� Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.� Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.� Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou-blée.

� N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ les pièces endommagées. Entretenir l’appareil conformé-ment à ce manuel.

� Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.� S’assurer que tous les panneaux et couvercles sont correctement

en place.� Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près pos-sible de la soudure.

� Isoler la pince de masse quand pas mis à la pièce pour éviter lecontact avec tout objet métallique.

� Ne pas raccorder plus d’une électrode ou plus d’un câble demasse à une même borne de sortie de soudage. Débrancher lecâble pour le procédé non utilisé.

� Utiliser une protection différentielle lors de l’utilisation d’un équi-pement auxiliaire dans des endroits humides ou mouillés.

Il reste une TENSION DC NON NÉGLIGEABLE dansles sources de soudage onduleur UNE FOISl’alimentation coupée.� Arrêter les convertisseurs, débrancher le courant électrique et

décharger les condensateurs d’alimentation selon les instructionsindiquées dans la partie Entretien avant de toucher les pièces.

OM-235281 Page 6

LES PIÈCES CHAUDES peuventprovoquer des brûlures.� Ne pas toucher à mains nues les parties chaudes.� Prévoir une période de refroidissement avant

de travailler à l’équipement.

� Ne pas toucher aux pièces chaudes, utiliser les outils recomman-dés et porter des gants de soudage et des vêtements épais pouréviter les brûlures.

LES FUMÉES ET LES GAZ peuventêtre dangereux.

Le soudage génère des fumées et des gaz. Leurinhalation peut être dangereux pour votre santé.

� Eloigner votre tête des fumées. Ne pas respirer les fumées.� À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz desoudage. Pour déterminer la bonne ventilation, il est recommandéde procéder à un prélèvement pour la composition et la quantitéde fumées et de gaz auxquels est exposé le personnel.

� Si la ventilation est médiocre, porter un respirateur anti-vapeursapprouvé.

� Lire et comprendre les fiches de données de sécurité et les instruc-tions du fabricant concernant les adhésifs, les revêtements, lesnettoyants, les consommables, les produits de refroidissement, lesdégraisseurs, les flux et les métaux.

� Travailler dans un espace fermé seulement s’il est bien ventilé ouen portant un respirateur à alimentation d’air. Demander toujours àun surveillant dûment formé de se tenir à proximité. Des fumées etdes gaz de soudage peuvent déplacer l’air et abaisser le niveaud’oxygène provoquant des blessures ou des accidents mortels.S’assurer que l’air de respiration ne présente aucun danger.

� Ne pas souder dans des endroits situés à proximité d’opérationsde dégraissage, de nettoyage ou de pulvérisation. La chaleur etles rayons de l’arc peuvent réagir en présence de vapeurs et for-mer des gaz hautement toxiques et irritants.

� Ne pas souder des métaux munis d’un revêtement, tels que l’aciergalvanisé, plaqué en plomb ou au cadmium à moins que le revête-ment n’ait été enlevé dans la zone de soudure, que l’endroit soitbien ventilé, et en portant un respirateur à alimentation d’air. Lesrevêtements et tous les métaux renfermant ces éléments peuventdégager des fumées toxiques en cas de soudage.

LES RAYONS DE L’ARC peuventprovoquer des brûlures dans lesyeux et sur la peau.Le rayonnement de l’arc du procédé de soudage génèredes rayons visibles et invisibles intenses (ultraviolets e

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur lapeau. Des étincelles sont projetées pendant le soudage.

� Porter un casque de soudage approuvé muni de verres filtrantsapproprié pour protéger visage et yeux pour protéger votre visageet vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1et Z87.1 énuméré dans les normes de sécurité).

� Porter des lunettes de sécurité avec écrans latéraux même sousvotre casque.

� Avoir recours à des écrans protecteurs ou à des rideaux pourprotéger les autres contre les rayonnements les éblouissementset les étincelles ; prévenir toute personne sur les lieux de ne pasregarder l’arc.

� Porter un équipement de protection pour le corps fait d’un matériaurésistant et ignifuge (cuir, coton robuste, laine). La protection ducorps comporte des vêtements sans huile comme par ex. desgants de cuir, une chemise solide, des pantalons sans revers, deschaussures hautes et une casquette.

LE SOUDAGE peut provoquer unincendie ou une explosion.Le soudage effectué sur des conteneurs fermés telsque des réservoirs, tambours ou des conduites peutprovoquer leur éclatement. Des étincelles peuvent

être projetées de l’arc de soudure. La projection d’étincelles, des

pièces chaudes et des équipements chauds peut provoquer des incen-dies et des brûlures. Le contact accidentel de l’électrode avec desobjets métalliques peut provoquer des étincelles, une explosion, un sur-

chauffement ou un incendie. Avant de commencer le soudage, vérifieret s’assurer que l’endroit ne présente pas de danger.� Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrirsoigneusement avec des protections homologués.

� Ne pas souder dans un endroit là où des étincelles peuvent tombersur des substances inflammables.

� Se protéger et d’autres personnes de la projection d’étincelles etde métal chaud.

� Des étincelles et des matériaux chauds du soudage peuventfacilement passer dans d’autres zones en traversant de petitesfissures et des ouvertures.

� Surveiller tout déclenchement d’incendie et tenir un extincteur àproximité.

� Le soudage effectué sur un plafond, plancher, paroi ou séparationpeut déclencher un incendie de l’autre côté.

� Ne pas effectuer le soudage sur des conteneurs fermés tels quedes réservoirs, tambours, ou conduites, à moins qu’ils n’aient étépréparés correctement conformément à AWS F4.1 et AWS A6.0(voir les Normes de Sécurité).

� Ne pas souder là où l’air ambiant pourrait contenir des poussières,gaz ou émanations inflammables (vapeur d’essence, par exemple).

� Brancher le câble de masse sur la pièce le plus près possible de lazone de soudage pour éviter le transport du courant sur unelongue distance par des chemins inconnus éventuels en provo-quant des risques d’électrocution, d’étincelles et d’incendie.

� Ne pas utiliser le poste de soudage pour dégeler des conduites ge-lées.

� En cas de non utilisation, enlever la baguette d’électrode du porte-électrode ou couper le fil à la pointe de contact.

� Porter un équipement de protection pour le corps fait d’un matériaurésistant et ignifuge (cuir, coton robuste, laine). La protection ducorps comporte des vêtements sans huile comme par ex. desgants de cuir, une chemise solide, des pantalons sans revers, deschaussures hautes et une casquette.

� Avant de souder, retirer toute substance combustible de vos po-ches telles qu’un allumeur au butane ou des allumettes.

� Une fois le travail achevé, assurez−vous qu’il ne reste aucunetrace d’étincelles incandescentes ni de flammes.

� Utiliser exclusivement des fusibles ou coupe−circuits appropriés.Ne pas augmenter leur puissance; ne pas les ponter.

� Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) etNFPA 51B pour les travaux à chaud et avoir de la surveillance et unextincteur à proximité.

� Lire et comprendre les fiches de données de sécurité et les instruc-tions du fabricant concernant les adhésifs, les revêtements, lesnettoyants, les consommables, les produits de refroidissement,les dégraisseurs, les flux et les métaux.

DES PIECES DE METAL ou DESSALETES peuvent provoquer desblessures dans les yeux.

� Le soudage, l’écaillement, le passage de la pièce àla brosse en fil de fer, et le meulage génèrent des étincelles et desparticules métalliques volantes. Pendant la période de ref-roidissement des soudures, elles risquent de projeter du laitier.

� Porter des lunettes de sécurité avec écrans latéraux ou un écranfacial.

LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou même la mort.� Fermer l’alimentation du gaz comprimé en cas

de non utilisation.

� Veiller toujours à bien aérer les espaces confinés ou se servir d’unrespirateur d’adduction d’air homologué.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)peuvent affecter les implants médicaux.

� Les porteurs de stimulateurs cardiaques etautres implants médicaux doivent rester àdistance.

� Les porteurs d’implants médicaux doivent consulter leur médecinet le fabricant du dispositif avant de s’approcher de la zone où sedéroule du soudage à l’arc, du soudage par points, du gougeage,de la découpe plasma ou une opération de chauffage parinduction.

OM-235281 Page 7

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peutaffecter l’ouïe.� Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

Les bouteilles de gaz comprimé contiennent dugaz sous haute pression. Si une bouteille estendommagée, elle peut exploser. Du fait que

les bouteilles de gaz font normalement partie du procédé desoudage, les manipuler avec précaution.

LES BOUTEILLES peuvent explosersi elles sont endommagées.

� Protéger les bouteilles de gaz comprimé d’une chaleur excessive,des chocs mécaniques, des dommages physiques, du laitier, desflammes ouvertes, des étincelles et des arcs.

� Placer les bouteilles debout en les fixant dans un support station-naire ou dans un porte-bouteilles pour les empêcher de tomber oude se renverser.

� Tenir les bouteilles éloignées des circuits de soudage ou autrescircuits électriques.

� Ne jamais placer une torche de soudage sur une bouteille à gaz.� Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.� Ne jamais souder une bouteille pressurisée − risque d’explosion.� Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

tuyaux et raccords convenables pour cette application spécifique;les maintenir ainsi que les éléments associés en bon état.

� Tourner le dos à la sortie de vanne lors de l’ouverture de la vannede la bouteille. Ne pas se tenir devant ou derrière le régulateur lorsde l’ouverture de la vanne.

� Le couvercle du détendeur doit toujours être en place, sauf lorsquela bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

� Utiliser les équipements corrects, les bonnes procédures et suffi-samment de personnes pour soulever et déplacer les bouteilles.

� Lire et suivre les instructions sur les bouteilles de gaz comprimé,l’équipement connexe et le dépliant P-1 de la CGA (Compressed GasAssociation) mentionné dans les principales normes de sécurité.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLOSION.� Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.� Ne pas installer l’appareil à proximité de pro-

duits inflammables.� Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avantde mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peutprovoquer des blessures.� Utiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, lesbouteilles de gaz ou tout autre accessoire.

� Utiliser un équipement de levage de capacité suffisante pour leverl’appareil.

� En utilisant des fourches de levage pour déplacer l’unité, s’assurerque les fourches sont suffisamment longues pour dépasser ducôté opposé de l’appareil.

� Tenir l’équipement (câbles et cordons) à distance des véhiculesmobiles lors de toute opération en hauteur.

� Suivre les consignes du Manuel des applications pour l’équationde levage NIOSH révisée (Publication Nº94–110) lors du levagemanuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peutSURCHAUFFER L’ÉQUIPEMENT.� Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.� Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.� Ne pas obstruer les passages d’air du poste.

LES ÉTINCELLES PROJETÉESpeuvent provoquer des blessures.� Porter un écran facial pour protéger le visage et

les yeux.� Affûter l’électrode au tungstène uniquement à

la meuleuse dotée de protecteurs. Cette manœuvre est à exé-cuter dans un endroit sûr lorsque l’on porte l’équipement ho-mologué de protection du visage, des mains et du corps.

� Les étincelles risquent de causer un incendie − éloigner toutesubstance inflammable.

LES CHARGES ÉLECTROSTATI-QUES peuvent endommager les cir-cuits imprimés.� Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

� Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-placer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuventcauser des blessures.� Ne pas s’approcher des organes mobiles.� Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuventprovoquer des blessures.� Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.� Ne pas diriger le pistolet vers soi, d’autres

personnes ou toute pièce mécanique en engageant le fil desoudage.

L’EXPLOSION DE LA BATTERIEpeut provoquer des blessures.

� Ne pas utiliser l’appareil de soudage pour charger des batteries ou faire démarrer desvéhicules à l’aide de câbles de démarrage,sauf si l’appareil dispose d’une fonctionnalitéde charge de batterie destinée à cet usage.

Les PIÈCES MOBILES peuventcauser des blessures.� S’abstenir de toucher des organes mobiles tels

que des ventilateurs.� Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs de protection.

� Lorsque cela est nécessaire pour des travaux d’entretien et de dé-pannage, faire retirer les portes, panneaux, recouvrements oudispositifs de protection uniquement par du personnel qualifié.

� Remettre les portes, panneaux, recouvrements ou dispositifs deprotection quand l’entretien est terminé et avant de rebrancherl’alimentation électrique.

LIRE LES INSTRUCTIONS.� Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’instal-lation, l’utilisation ou l’entretien de l’appareil.Lire les informations de sécurité au début dumanuel et dans chaque section.

� N’utiliser que les pièces de rechange recommandées par leconstructeur.

� Effectuer l’installation, l’entretien et toute intervention selon lesmanuels d’utilisateurs, les normes nationales, provinciales et del’industrie, ainsi que les codes municipaux.

OM-235281 Page 8

LE RAYONNEMENT HAUTEFRÉQUENCE (H.F.) risque deprovoquer des interférences.

� Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équi-

pements de radio−navigation et de communication, les servicesde sécurité et les ordinateurs.

� Demander seulement à des personnes qualifiées familiarisées avecdes équipements électroniques de faire fonctionner l’installation.

� L’utilisateur est tenu de faire corriger rapidement par un électricienqualifié les interférences résultant de l’installation.

� Si le FCC signale des interférences, arrêter immédiatement l’appareil.

� Effectuer régulièrement le contrôle et l’entretien de l’installation.

� Maintenir soigneusement fermés les portes et les panneaux dessources de haute fréquence, maintenir les éclateurs à une distan-ce correcte et utiliser une terre et un blindage pour réduire lesinterférences éventuelles.

LE SOUDAGE À L’ARC risque deprovoquer des interférences.� L’énergie électromagnétique risque de

provoquer des interférences pour l’équipementélectronique sensible tel que les ordinateurs etl’équipement commandé par ordinateur tel queles robots.

� Veiller à ce que tout l’équipement de la zone de soudage soit com-patible électromagnétiquement.

� Pour réduire la possibilité d’interférence, maintenir les câbles desoudage aussi courts que possible, les grouper, et les poser aussibas que possible (ex. par terre).

� Veiller à souder à une distance de 100 mètres de tout équipementélectronique sensible.

� Veiller à ce que ce poste de soudage soit posé et mis à la terreconformément à ce mode d’emploi.

� En cas d’interférences après avoir pris les mesures précédentes,il incombe à l’utilisateur de prendre des mesures supplémentairestelles que le déplacement du poste, l’utilisation de câbles blindés,l’utilisation de filtres de ligne ou la pose de protecteurs dans la zonede travail.

2-4. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent desfumées et des gaz qui contiennent des produits chimiquesdont l’État de Californie reconnaît qu’ils provoquent des mal-formations congénitales et, dans certains cas, des cancers.(Code de santé et de sécurité de Californie, chapitre 25249.5et suivants)

Ce produit contient des produits chimiques, notamment duplomb, dont l’État de Californie reconnaît qu’ils provoquentdes cancers, des malformations congénitales ou d’autresproblèmes de procréation. Se laver les mains aprèsutilisation.

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,is available as a free download from the American Welding Society athttp://www.aws.org or purchased from Global Engineering Documents(phone: 1-877-413-5184, website: www.global.ihs.com).Safe Practices for the Preparation of Containers and Piping for Weldingand Cutting, American Welding Society Standard AWS F4.1, from Glob-al Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).Safe Practices for Welding and Cutting Containers that have Held Com-bustibles, American Welding Society Standard AWS A6.0, from GlobalEngineering Documents (phone: 1-877-413-5184,website: www.global.ihs.com).National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:www.nfpa.org and www. sparky.org).Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 14501 George Carter Way, Suite103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga-net.com).Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS(phone: 800-463-6727, website: www.csagroup.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, from American National Standards Institute,25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-site: www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, from National Fire Protection Association,Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website:www.osha.gov).Applications Manual for the Revised NIOSH Lifting Equation, The Na-tional Institute for Occupational Safety and Health (NIOSH), 1600Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champsélectromagnétiques (CEM) à certains endroits. Le courant issu d’unsoudage à l’arc (et de procédés connexes, y compris le soudage parpoints, le gougeage, le découpage plasma et les opérations dechauffage par induction) crée un champ électromagnétique (CEM)autour du circuit de soudage. Les champs électromagnétiques produitspeuvent causer interférence à certains implants médicaux, p. ex. lesstimulateurs cardiaques. Des mesures de protection pour les porteursd’implants médicaux doivent être prises: Limiter par exemple tout accèsaux passants ou procéder à une évaluation des risques individuels pourles soudeurs. Tous les soudeurs doivent appliquer les procéduressuivantes pour minimiser l’exposition aux CEM provenant du circuit desoudage:

1. Rassembler les câbles en les torsadant ou en les attachant avecdu ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

câbles d’un côté et à distance de l’opérateur.3. Ne pas courber et ne pas entourer les câbles autour de votre

corps.4. Maintenir la tête et le torse aussi loin que possible du matériel du

circuit de soudage.5. Connecter la pince sur la pièce aussi près que possible de la

soudure.6. Ne pas travailler à proximité d’une source de soudage, ni

s’asseoir ou se pencher dessus.7. Ne pas souder tout en portant la source de soudage ou le

dévidoir.En ce qui concerne les implants médicaux :Les porteurs d’implants doivent d’abord consulter leur médecin avantde s’approcher des opérations de soudage à l’arc, de soudage parpoints, de gougeage, du coupage plasma ou de chauffage par induc-tion. Si le médecin approuve, il est recommandé de suivre lesprocédures précédentes.

� A complete Parts List is available on-line at www.HobartWelders.com

OM-235281 Page 9

SECTION 3 − DEFINITIONS3-1. Additional Safety Symbols And Definitions� Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Safe1 2012−05

Drive rolls can injure fingers.

Safe32 2012−05

Falling unit can cause injury and damage. Do not move unit where two wheels are at a different height and unitcould tip − avoid tipping. Be careful when moving unit over uneven surfaces.

Safe98 2012−05

3-2. Miscellaneous Symbols And Definitions� Some symbols are found only on CE products.

A Amperage

Positive

Output

Do Not SwitchWhile Welding

U0Rated No LoadVoltage (OCV)

I1maxRated MaximumSupply Current

Temperature

SSuitable For

Welding In AnEnvironment WithIncreased Risk Of

Electric Shock

V Voltage

Direct Current(DC)

Voltage Input

Gas Metal ArcWelding (GMAW)

U1Primary Voltage

I2Rated Welding

Current

Increase

I1Rated Supply

Current

Hz Hertz

Single Phase

Off

Wire Feed

U2ConventionalLoad Voltage

X Duty Cycle

Percent

I1eff

Maximum Effect-ive Supply Cur-

rent

Negative

Input

On

Circuit Protector

Line Connection

Single PhaseTransformer-

Rectifier

Protective Earth(Ground)

MIG Gun/SpoolGun


OM-235281 Page 10

SECTION 4 − SPECIFICATIONS4-1. Serial Number And Rating Label LocationThe serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or ratedoutput. For future reference, write serial number in space provided on back cover of this manual.

4-2. Unit Specifications

� Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-10, 5-11, and 5-12 for informationon connecting input power.

� This equipment will deliver rated output at an ambient air temperature up to 104�F (40�C).

Rated OutputMax. Open

Circuit Voltage

Amps Input at Rated Output, 60 Hz, Single-Phase

200 V 230 V KVA KW

175 A at 25.5 VDC,60% Duty Cycle 38

37.02.4*

32.52.3*

7.40.54*

6.30.30*

* While idling.

Wire Type and Diameter

No LoadWire Feed

Speed Dimensions Weight

Solid Steel/Stainless Steel Aluminum Flux Cored

0−700 IPM(0−17.8m/min)

H: 32 in. (813 mm)W: 18-7/8 in. (479 mm)

D: 37 in. (940 mm)

185 lb(84 kg)

0.023 − 0.045 in.(0.6 − 1.2 mm)

0.030 − .0035 in.(0.8 − 0.9 mm)

0.030 − 0.045 in.(0.8 − 1.2 mm)

4-3. Welding Power Source Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orvoltage, or duty cycle beforewelding.

NOTICE − Exceeding duty cyclecan damage unit or gun and voidwarranty.

Overheating

6 Minutes Welding 4 Minutes Resting

0

15

A or V

ORReduce Duty Cycle

Minutes

duty1 4/95 − 227 953-A

30 40 50 60 70 80 90 10050

100

150

200

250

% DUTY CYCLE

WE

LD

AM

PE

RE

S

60%dutycycle


OM-235281 Page 11

4-4. Environmental SpecificationsA. Temperature Specifications

Operating Temperature Range* Storage/Transportation Temperature Range

14 to 104°F (−10 to 40°C)

*Output is derated at temperatures above 104°F (40°C).−4 to 131°F (−20 to 55°C)

Temp_2016- 07

4-5. Volt-Ampere Curves

Volt-ampere curves show minimumand maximum voltage and amper-age output capabilities of unit.Curves of other settings fall be-tween curves shown.

va_curve1 4/95 − 240 913-A

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

0 50 100 150 200 250 300

Vo

ltag

e

Amperage


OM-235281 Page 12

SECTION 5 − INSTALLATION

! Special installation may berequired where gasoline orvolatile liquids are present −see NEC Article 511 or CECSection 20.

1 Running Gear

2 Lifting Forks

Use running gear or lifting forks tomove unit.

If using lifting forks, extend forksbeyond opposite side of unit.

3 Line Disconnect Device

Locate unit near correct inputpower supply.

5-1. Selecting A Location

3

18 in(460 mm)

18 in(460 mm)

OR

2

Movement

Location And Airflow

Ref.-loc_cart mount 2015-08

1

! Do not move or operate unitwhere it could tip.

5-2. Installing Welding Gun

Ref. 242 143-B

1 Drive Assembly

2 Gun Securing Knob

3 Gun End

Loosen knob. Insert gunend through opening until itbottoms against drive as-sembly. Tighten knob.

4 Gun Trigger Plug

Insert plug into receptacle,and tighten threaded collar.

5 MIG/Spool GunSwitch

Switch is shown in MIG po-sition.

Close door.

2

1

3

4

5


OM-235281 Page 13

5-3. Connecting Weld Output Cables

803 778-B

! Turn off power before connecting toweld output terminals.

! Failure to properly connect weld ca-bles may cause excessive heat andstart a fire, or damage your machine.

� Do not place anything between weldcable terminal and copper bar. Make

sure that the surfaces of the weld cableterminal and copper bar are clean.

1 Correct Weld Cable Connection

2 Incorrect weld Cable Connection

3 Weld Output Terminal

4 Supplied Weld Output Terminal Nut

5 Weld Cable Terminal

6 Copper Bar

Remove supplied nut from weld output ter-minal. Slide weld cable terminal onto weldoutput terminal and secure with nut so thatweld cable terminal is tight against copperbar.

Tools Needed:

3/4 in. (19 mm)

4

2

31

5

6

connecting weld output cables 3−2010

5-4. Installing Work Clamp

1 Work Cable

Route cable out front panel openingfrom inside.

2 Negative (−/Black) OutputTerminal

Connect cable to terminal.

3 Hardware

4 Work Clamp

Route cable through clamp handleand secure as shown.

Close door.

Ref. 242 145-B

Tools Needed:

1/2, 3/4 in.

1 3

4

2


OM-235281 Page 14

5-5. Setting Gun Polarity For Wire Type

Tools Needed:

3/4 in.Ref. 242 145-A

Shown as shipped - Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or fluxcore with gas wires (GMAW).

Electrode Negative (DCEN): Reverse lead connections at terminals from thatshown above for gasless flux core wires (FCAW).Drive assembly becomes negative.

+ Positive Terminal

− Negative TerminalWork Clamp Lead

Wire Drive Assembly Lead

Changing Polarity

5-6. Installing 2 lb Wire Spool And Adjusting Hub Tension

242 146-A

1 Keyed Washer

2 Wire Spool (2 LB)

3 Keyed Washer

4 Compression Spring

5 Washer

6 Nut

Assemble components in numer-ical order as shown.

Hand tighten nut to create a slightdrag while rotating wire spool.

� Over tightening nut maycause wire slippage.

1

2

3

4

56


OM-235281 Page 15


242 147-A

1 Spool Hub

2 Spool Hub Adapter

3 Spool Hub Nut

4 Keyed Washer (2)


6 Washer7 Nut


Slide spool hub adapter up on hubfor the smaller spool making sureit is positioned in the anti-rotationnotches.

Secure hub nut on spool hub ad-aptor.

Position remaining components.



2

1

3

4

5

67


242 148-A

1 Spool Hub

2 Spool Hub Adapter

3 Spool Hub Nut

4 Keyed Washer (2)


6 Washer7 Nut


Slide spool hub adapter up on hubfor the smaller spool making sureit is positioned in the anti-rotationnotches.

Secure hub nut on spool hub ad-aptor.

Position remaining components.



2

1

3

4

5

67


OM-235281 Page 16

5-9. Installing Gas Supply

242 687-B

Tools Needed:

1-1/8, 5/8 or 11/16 in.

Rear Panel

� DO NOT use Argon/Mixed gas regulator/flowmeterwith CO2 shielding gas. See Parts List for optionalCO2 gas regulator/flowmeter.

Obtain gas cylinder and chain torunning gear, wall, or other stationarysupport so cylinder cannot fall andbreak off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of valve,and open valve slightly. Gas flowblows dust and dirt from valve. Closevalve.

3 Cylinder

a Argon Or Mixed Gas Cylinder

b CO2 Cylinder

4 Regulator/Flowmeter − InstalledSo That Face Is Vertical

a Argon Or Mixed Gas Regulator/Flowmeter

b CO2 Regulator/Flowmeter

Install so face is vertical.

5 Regulator/Flowmeter Gas HoseConnection

6 Welding Power Source GasHose Connection For MIG Gun

Connect customer supplied gas hosebetween regulator/flowmeter gashose connection, and fitting on rear ofwelding power source.

7 Gas Flow Adjustment Control

Typical flow rate is 20 cfh (cubicfeet per hour). Check wiremanufacturer’s recommended flowrate.

1

2

3a

4a

5 7Argon Gas OrMixed Gas

6

2

3b

4b

5 7 CO2 Gas


OM-235281 Page 17

5-10. Positioning Jumper Links

242 688-B

! Turn off and disconnect inputpower.

Check input voltage available at site.

1 Jumper Links Access Door

Open door.

2 Jumper Link Label

Check label − only one is on unit.

3 Input Voltage Jumper Links

Move jumper links to match inputvoltage.

Close and secure access door.

3

Tools Needed:

2

3/8 in.

200 VOLTS

230 VOLTS

S-153 980

1

5-11. Electrical Service Guide Elec Serv 2014−01

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the ratingof the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and630.12.

60 Hz SinglePhase

Input Voltage (V) 200 230

Input Amperes (A) At Rated Output 37.0 32.5

Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay Fuses 2 45 40

Normal Operating Fuses 3 60 50

Min Input Conductor Size In AWG 4 10 10

Max Recommended Input Conductor Length In Feet (Meters)77

(23)102(31)

Min Grounding Conductor Size In AWG 4 10 10

Reference: 2014 National Electrical Code (NEC) (including article 630)1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.

2 “Time-Delay” fuses are UL class “RK5” . See UL 248.3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above).4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cablerequirements.


OM-235281 Page 18

5-12. Connecting 1-Phase Input Power

input4 2012−05 − Ref. 803 766-C / Ref. 242 691-A / Ref. 802 286-E

L1L2

230 VAC, 1

98

1

2

1

L1L2

1

=GND/PE Earth Ground

6

5

3

4

7

Tools Needed:


OM-235281 Page 19

input4 2012−05 − 803 766-C

! Installation must meet all National andLocal Codes − have only qualified per-sons make this installation.

! Disconnect and lockout/tagout inputpower before connecting input con-ductors from unit. Follow establishedprocedures regarding the installationand removal of lockout/tagoutdevices.

! Always connect green or green/yellowconductor to supply grounding termi-nal first, and never to a line terminal.

See rating label on unit and check input volt-age available at site.

1 Input Power Cord

2 Disconnect Device (switch shown in theOFF position)

3 Disconnect Device Grounding Terminal

4 Disconnect Device Line Terminals

5 Black And White Input Conductor (L1And L2)

6 Green Or Green/Yellow GroundingConductor

Connect green or green/yellow groundingconductor to disconnect device groundingterminal first.

Connect input conductors L1 and L2 to dis-connect device line terminals.

7 Over-Current Protection

Select type and size of over-current protec-tion using Section 5-11 (fused disconnectswitch shown).

8 Plug (NEMA Type 6-50P)

9 Receptacle NEMA Type 6-50R)

Connect plug to receptacle.

Close and secure door on disconnect device.Follow established lockout/tagout proced-ures to put unit in service.

5-12. Connecting 1-Phase Input Power (Continued)

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.


OM-235281 Page 20

5-13. Threading Welding Wire

1 Wire Spool

2 Welding Wire

3 Inlet Wire Guide

4 Pressure Adjustment Knob

5 Drive Roll

6 Outlet Wire Guide7 Gun Conduit Cable

Lay gun cable out straight beforethreading wire.

7

Tools Needed:

6 in.(150 mm)

� Hold wire tightly to keep itfrom unraveling.

WOOD

Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;continue to hold wire.

Close and tighten pressure assembly, and let go of wire.

Lay gun cable out straight andremove gun nozzle and contact tip.

Turn power ON.

Press gun trigger until wire comes out of gun. Reinstall

contact tip and nozzle

Feed wire to check drive roll pressure.Tighten knob enough to prevent slipping.

Cut off wire approximately 5/16 in.(8 mm) from contact tip. Close door.

242 692-B

� Hold wire in groove beforeclosing pressure assembly.

Tighten

3 5 621

4

ON

OFF

POWER

ON


OM-235281 Page 21

5-14. Installing Optional DP 3545 Spool Gun To Welding Power Source

242 143-B / 242 154-A

! Turn Off unit, and disconnectinput power.

1 Drive Assembly

2 Spool Gun

3 Gun Securing Thumbscrew

4 Gun End

Loosen thumbscrew. Insert gunend through opening until it bottomsagainst drive assembly. Tightenthumbscrew.

� Spool gun must be insertedcompletely to prevent leakageof shielding gas.

5 Gun Trigger Plug

Insert plug into receptacle, andtighten threaded collar.

6 Spool Gun/MIG Gun Switch

Place switch in Spool Gun position.

7 Polarity Change OverTerminal Block

To make proper polarity connectionsee Section 5-5.

Close door.

8 Wire Feed Speed Control

Wire feed speed is controlled bywelding power source Wire FeedSpeed control (see Section 6-1).

9 Voltage Control

Arc voltage is controlled by weldingpower source Voltage control (seeSection 6-1).

10 Trigger

Press trigger to energize weldingpower source contactor, startshielding gas flow, and begin wirefeed.

9

810

2 1 3

4

5

7

6


OM-235281 Page 22

SECTION 6 − OPERATION

6-1. Controls

1 Wire Speed Control

Control varies the rate of wire beingfed through the welding gun.

2 Voltage Control

Control varies the voltage level ofthe welding arc. The voltage rangeis 1 (minimum) to 12 (maximum).

3 Power Switch

The fan is thermostaticallycontrolled and only runs whencooling is needed.

4 Power Light

5 Gun Trigger Receptacle

Ref. 235 267-B

1

4

3

5

OFF

1


OM-235281 Page 23

6-2. Weld Parameters

Sel

ectin

g W

ire, G

as a

nd C

ontr

ol S

ettin

gs

Set

tin

gs

are

app

roxi

mat

e an

d a

re b

ased

on

a 2

30 In

pu

t lin

e vo

ltag

e. A

dju

st a

s re

qu

ired

.T

hic

ker

mat

eria

ls c

an b

e w

eld

ed u

sin

g p

rop

er t

ech

niq

ue,

jo

int

pre

par

atio

n a

nd

mu

ltip

lep

asse

s.

.024

” (

0.6

mm

)

.030

” (

0.8

mm

)

.035

” (

0.9

mm

)

.045

” (

1.1

mm

).0

24”

( 0

.6m

m )

.030

” (

0.8

mm

)

.035

” (

0.9

mm

)

.045

” (

1.1

mm

).0

24”

( 0

.6m

m )

.030

” (

0.8

mm

)

.035

” (

0.9

mm

)

.045

” (

1.1

mm

).0

24”

( 0

.6m

m )

.030

” (

0.8

mm

)

.035

” (

0.9

mm

)

.045

” (

1.1

mm

).0

24”

( 0

.6m

m )

.030

” (

0.8

mm

)

.035

” (

0.9

mm

).0

24”

( 0

.6m

m )

.030

” (

0.8

mm

)

.035

” (

0.9

mm

).0

30”

( 0

.8m

m )

.035

” (

0.9

mm

)

.045

” (

1.1

mm

).0

30”

( 0

.8m

m )

.035

” (

0.9

mm

)

.047

” (

1.2

mm

)

.030

” ( 0

.8m

m )

035”

( 0

.9m

m )

.047

” ( 1

.2m

m )

Dia

met

erof

Wire

Bei

ng U

sed

C25

Gas

Mix

ture

75%

Ar

/ 25%

CO

2 P

rodu

ces

less

spa

tter

Bet

ter

App

eara

nce

92%

Ar

/8%

CO

2or

90%

Ar

/ 10%

CO

2

Tri–

Mix

90%

HE

/ 7.

5% A

r /

2.5%

CO

2

No

Shi

eldi

ng G

as R

equi

red

Goo

d fo

r W

indy

or

Out

door

App

licat

ions

100%

Arg

on**

100%

Arg

on**

Sug

gest

edS

hiel

ding

Gas

es20

–30

cfh

Flo

w R

ate

Sol

id W

ireE

R70

S–6

“Set

Pol

arity

”fo

r (D

CE

P)”

Sta

inle

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teel

“Set

Pol

arity

”fo

r (D

CE

P)”

Flu

x C

ore

E71

T–G

S“S

et P

olar

ity”

for

(DC

EN

)”

Alu

min

um**

4043

AL

(DC

EP

)

Alu

min

um**

5356

AL

(DC

EP

)

Wire

Typ

e,an

dP

olar

ityS

ettin

g

Ste

el

Sta

inle

ssS

teel

Ste

el

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min

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ith O

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nal

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5S

pool

gun

Mat

eria

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eing

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ded

2352

68A

Rec

om

men

ded

Vo

ltag

e an

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ire

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eed

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gs

for

Th

ickn

ess

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al B

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g W

eld

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um

ber

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t is

Vo

ltag

e S

etti

ng

/ N

um

ber

on

Rig

ht

is W

ire

Fee

d S

etti

ng

1/2

inch

( 12

.7m

m )

——

9 / 6

26

/ 38

7 / 3

0

——

7 / 7

07

/ 54

6 / 3

2

——

8 / 7

07

/ 46

6 / 3

4

——

8 / 6

28

/ 60

——

8 / 7

8

10 /

707

/ 54

8 / 5

0

9 / 5

010

/ 66

11 /

60

12 /

34

12 /

98

12 /

82

12 /

42

8 / 7

4

8 / 7

0

7 / 5

0

6 / 3

4—

—

9 / 6

26

/ 38

7 / 3

0

——

7 / 7

07

/ 54

6 / 3

2

——

8 / 7

07

/ 46

6 / 3

4

——

8 / 6

28

/ 60

——

7 / 7

6

10 /

70

7 / 5

4

8 / 5

0

8 / 4

49

/ 60

10 /

52

11 /

30

10 /

82

10 /

58

11 /

38

3/8

inch

( 9.

5mm

)

7 / 7

0

7 / 6

0

6 / 4

4

6 / 3

49

/ 90

8 / 5

0

6 / 3

8

7 / 3

0

——

7 / 7

07

/ 54

6 / 3

2

——

7 / 6

07

/ 46

6 / 3

4

——

8 / 6

28

/ 60

——

6 / 7

69

/ 62

7 / 5

47

/ 44

7 / 3

8

8 / 4

6

9 / 5

0

10 /

26

9 / 7

6

9 / 5

4

10 /

34

1/4

inch

( 6.

3mm

)

6 / 7

0

6 / 4

6

5 / 4

0

5 / 2

68

/ 74

7 / 4

6

6 / 3

6

7 / 3

0

——

6 / 6

06

/ 42

5 / 3

0

——

6 / 4

66

/ 40

5 / 3

2

——

8 / 6

27

/ 58

——

6 / 6

89

/ 60

6 / 5

06

/ 40

6 / 3

27

/ 42

8 / 4

0

9 / 2

4

8 / 6

0

8 / 4

6

9 / 3

4

3/16

inch

( 4.

8mm

)

5 / 5

0

5 / 3

6

5 / 3

4

4 / 2

47

/ 70

6 / 4

6

5 / 3

4

6 / 2

6

——

5 / 4

05

/ 40

5 / 2

6

5 / 5

8

5 / 3

6

5 / 4

0

5 / 3

06

/ 60

7 / 6

0

6 / 5

0

6 / 8

0

4 / 5

2

7 / 6

45

/ 44

5 / 3

8

5 / 2

86

/ 40

7 / 3

4—

—

6 / 5

0

7 / 4

4

7 / 2

8

1/8

inch

( 3.

2mm

)

4 / 4

0

4 / 3

0

3 / 3

0

3 / 2

25

/ 46

5 / 4

0

4 / 2

8

4 / 1

8

4 / 4

4

4 / 3

4

3 / 3

4

3 / 2

24

/ 40

4 / 3

0

3 / 3

2

3 / 2

25

/ 48

5 / 3

6

5 / 4

4

3 / 4

4

3 / 4

0

4 / 4

03

/ 34

3 / 2

6

3 / 2

03

/ 36

4 / 3

4—

—

3 / 3

6

4 / 3

6—

—

14 g

auge

.075

inch

( 2.

0mm

)

3 / 4

0

3 / 3

4

3 / 2

6

2 / 2

04

/ 40

4 / 3

6

4 / 2

4

3 / 1

8

3 / 4

0

3 / 3

4

3 / 2

6

2 / 2

03

/ 40

3 / 3

4

3 / 2

8

2 / 2

04

/ 46

4 / 3

6

4 / 3

6

2 / 3

8

2 / 3

6

3 / 3

62

/ 26

2 / 2

0—

—2

/ 36

3 / 3

0—

—

2 / 3

6

3 / 3

6—

—

16 g

auge

.062

inch

( 1.

6mm

)

3 / 3

4

3 / 3

0

2 / 3

0—

—

4 / 3

4

3 / 3

6

3 / 2

4—

—

3 / 3

6

3 / 3

0

2 / 2

4—

—

3 / 3

6

3 / 3

0

2 / 2

6—

—

4 / 4

0

4 / 3

2

3 / 3

2

2 / 3

4

2 / 3

2

3 / 3

41

/ 24

——

——

——

2 / 2

4—

—

——

——

——

18 g

auge

.048

inch

( 1.

2mm

)

2 / 2

6

1 / 2

6

——

——

2 / 2

6

——

——

——

1 / 3

2

1 / 2

6—

—

——

1 / 3

2

1 / 2

6—

—

——

2 / 3

0

2 / 3

0

2 / 2

6

1 / 2

8

1 / 3

0

2 / 2

6—

—

——

——

——

——

——

——

——

——

22 g

auge

.030

inch

( 0.

8mm

)

1 / 2

2

1 / 2

0

——

——

2 / 2

4

——

——

——

1 / 3

0

1 / 2

0—

—

——

1 / 3

0

1 / 2

0—

—

——

——

——

——

——

——

——

——

——

——

——

——

——

——

——

——

24 g

auge

.024

inch

( 0.

6mm

)

9 / 9

0

9 / 7

6

7 / 5

0

6 / 3

4

98%

Ar /

2%

CO

2

98%

Ar

/ 2%

CO

2

100%

CO

2


OM-235281 Page 24

SECTION 7 − MAINTENANCE AND TROUBLESHOOTING

7-1. Routine Maintenance

! Disconnect power beforemaintaining.

� Maintain more often during se-vere conditions.

� = Check � = Change � = Clean � = Replace* To be done by Factory Authorized Service Agent

Every3Months

� Damaged Or UnreadableLabels

� Cracked Parts � � Cables � � Tighten WeldTerminal

Every6Months

OR

� Inside Unit � Remove drive rolland apply light coatof oil or grease todrive motor shaft

7-2. Supplementary Protectors

Ref. 242 160-B

! Turn Off unit.

1 Supplementary Protector CB1

CB1 protects main circuit board PC1.

2 Supplementary Protector CB2

CB2 protects the drive motor circuitfrom overload. If drive motor shorts orfails: check gun liner blockage orkinks, check for jammed wire or bind-ing drive rolls.

Correct problem. Press button to resetsupplementary protector.

2

1


OM-235281 Page 25

7-3. Replacing Drive Roll And Wire Inlet Guide

242 533-A

1 Securing Screw

2 Inlet Wire Guide

Loosen screw. Slide tip as close todrive rolls as possible withouttouching. Tighten screw.

3 Drive Roll

The drive roll consists of two differ-ent sized grooves. The stampedmarkings on the outer surface of thefoll refers to the groove on theopposite side of the drive roll. Thegroove closest to the motor shaft isthe proper groove to thread wire(see Section 5-13).

4 Drive Roll Securing Nut

Turn nut one click to secure driveroll.

1

2

3

4

7-4. Removing Knob From Front Panel

! Turn Off power.

1 Front Panel

2 Knob

3 Spring Clip

4 Control Shaft

5 Slot

Rotate knob to allow access to slot.Insert Allen wrench (or stiff piece ofwire) into slot, and while depressingspring clip, slide knob off controlshaft.

To reinstall, push knob fully ontocontrol shaft.

242 693-A

12

43

5

DepressSpring

Clip

SlideKnob


OM-235281 Page 26

7-5. Aligning Drive Rolls and Wire Guide

! Turn Off power.

View is from top of drive rolls look-ing down with pressure assemblyopen.

1 Drive Roll Securing Nut

2 Drive Roll

3 Wire Guide

4 Welding Wire5 Drive Gear

Insert screwdriver, and turn screwin or out until drive roll groove linesup with wire guide.

Close pressure roll assembly.

Ref. 800 412-A

Correct Incorrect43

21

5

Tools Needed:

7-6. Replacing Gun Contact Tip

Ref. 242 164-A

! Turn Off power beforereplacing contact tip.

1 Nozzle

2 Contact Tip

Cut off welding wire at contact tip.Remove nozzle.

Remove contact tip and install newcontact tip. Reinstall nozzle.

Tools Needed:

1

2

7-7. Installing Cable Hangers

Ref. 242 165-A

! Turn Off power beforeinstalling cable hangers.

1 Cable Hanger

2 Screws

Tools Needed:

1

2


OM-235281 Page 27

7-8. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning GunCasing

242 207-A

! Turn off welding powersource/wire feeder.

1 Nozzle

2 Contact Tip

3 Tip Adapter

4 Nozzle Adapter

� Wire size stamped on tip −check and match wire size.

HeadTube

Tools Needed:

5/8, 7/16 in.

Lay gun cable outstraight beforeinstalling new liner.

Remove nozzle,contact tip, andadapter.

Unscrew andremove liner.

Blow outgun casing.

Cut off wire anddisconnect gunfrom feeder.7/16 in

3/4 in.(20 mm)

LinerStickout

InstallLiner

� Thread wire according towelding power source/wirefeeder manual.

Reassemble gun inreverse order fromtaking it apart.

1

432

5/8 in


OM-235281 Page 28

7-9. Welding Troubleshooting Table

Welding Trouble Remedy

No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 5-12).

Place Power switch in the ON position.

Place MIG/Spool Gun switch in the proper position.

Check and replace Power switch if necessary.

Check supplementary protectors CB1 and/or CB2, and reset if necessary (see Section 7-2).

Replace building line fuse or reset circuit breaker if open (see Section 5-12).

Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Sections 5-2 and/orParts List).

Thermostat open (overheating). Allow fan to run; the thermostat will close when the unit has cooled (seeSection 4-3).

No weld output; wire feeds. Connect work clamp to get good metal to metal contact.

Replace contact tip (see Section 7-6).

Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 5-12).

Low, high, or erratic wire speed. Readjust front panel settings (see Section 6-1).

Change to correct size drive roll (see Section 7-3).

Readjust drive roll pressure (see Section 5-13).

Replace inlet guide, contact tip, and/or liner if necessary (see Sections 7-3, 7-6 and/or 7-8).

7-10. Wire Drive/Gun Troubleshooting Table

Wire Drive/Gun Trouble Remedy

Electrode wire feeding stops duringwelding or wire feeding intermittently.

Straighten gun cable and/or replace damaged parts (see Section 7-8).

Adjust drive roll pressure (see Section 5-13).

Readjust hub tension (see Section 5-6).

Check supplementary protectors CB1 and/or CB2, and reset if necessary (see Section 7-2).

Replace contact tip if blocked (see Section 7-6).

Clean or replace wire inlet guide or liner if dirty or plugged (see Sections 7-3 and/or 7-8).

Replace drive roll if worn or slipping (see Section 7-3).

Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Section 5-2 and/orsee Parts List).

Check and clear any restrictions at drive assembly and liner (see Section 7-8).

Have nearest Factory Authorized Service Agent check drive motor.

OM-235281 Page 29

SECTION 8 − GMAW WELDING (MIG) GUIDELINES

Wire Feeder/Power Source

Workpiece

Gun

Regulator/Flowmeter

Gas

Shielding Gas

Work Clamp

8-1. Typical GMAW (MIG) Process Connections

! Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible.

GMAW1 2015−01 (GMAW Only) − Ref. 801 909-A

8-2. Typical GMAW (MIG) Process Control Settings

� These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be surethey comply to specifications.

3.5 x 125 A = 437 ipm

2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

30 − 90 A

40 − 145 A

50 − 180 A

Convert MaterialThickness toAmperage (A)

Material thickness determines weldparameters.

.035 in Recommendation Wire Speed(Approx.)

1/8 or 0.125 in.

(0.001 in. = 1 ampere)0.125 in. = 125 A

Wire Size Amperage Range

0.023 in.

0.030 in.

0.035 in.

Select Wire Size

WireSize

0.023 in.

0.030 in.

0.035 in.

3.5 in. per ampere

2 in. per ampere

1.6 in. per ampere

Select Wire Speed (Amperage)

125 A based on 1/8 in.material thickness

ipm = inches per minute

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage

Select Voltage

Voltage controls height andwidth of weld bead.

Wire speed (amperage) controls weldpenetration (wire speed = burn-off rate)

OM-235281 Page 30

8-3. Holding And Positioning Welding Gun

� Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm)past end of nozzle, and tip of wire is positioned correctly on seam.

1 Hold Gun and Control GunTrigger

2 Workpiece

3 Work Clamp

4 Electrode Extension (Stickout)Solid Wire − 3/8 to 1/2 in.

(9 to 13 mm)

5 Cradle Gun and Rest Hand onWorkpiece

23

5

4

90° 90°

0°-15°

45°

45°

1

0°-15°

S-0421-A

End View of Work Angle Side View of Gun Angle

GROOVE WELDS

End View of Work Angle Side View of Gun Angle

FILLET WELDS

8-4. Conditions That Affect Weld Bead Shape

� Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed(weld current), and voltage.

Slow

FILLET WELD ELECTODE EXTENSIONS (STICKOUT)ELECTRODE EXTENSIONS (STICKOUT)

GUN ANGLES AND WELD BEAD PROFILES

10° 10°

GUN TRAVEL SPEED S-0634

Push Perpendicular Drag

Short Normal Long Short Normal Long

Normal Fast

OM-235281 Page 31

8-5. Gun Movement During Welding

� Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps,a weave bead or multiple stringer beads works better.

1 Stringer Bead − SteadyMovement Along Seam

2 Weave Bead − Side To SideMovement Along Seam

3 Weave Patterns

Use weave patterns to cover a widearea in one pass of the electrode.

S-0054-A

3

1 2

8-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits

2 Rough, Uneven Bead

3 Slight Crater During Welding

4 Bad Overlap

5 Poor Penetration

5

42 3

1

S-0053-A

8-7. Good Weld Bead Characteristics

1 Fine Spatter

2 Uniform Bead

3 Moderate Crater DuringWelding

Weld a new bead or layer for each1/8 in. (3.2 mm) thickness in metalsbeing welded.

4 No Overlap

5 Good Penetration into BaseMetal

S-0052-B

2 3

1

4

5

OM-235281 Page 32

8-8. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles thatcool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.

8-9. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pocketsin weld metal.

S-0635


Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

8-10. Troubleshooting − Excessive Penetration

Good Penetration

Excessive Penetration − weld metal melting through base metaland hanging underneath weld.

Excessive PenetrationS-0639


Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase travel speed.

OM-235281 Page 33

8-11. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallowfusion between weld metal andbase metal.

Lack of Penetration Good PenetrationS-0638


Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove whilemaintaining proper welding wire extension and arc characteristics.

Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.

8-12. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely withbase metal or a preceeding weld bead.

S-0637


Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface beforewelding.

Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

8-13. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metalresulting in holes where no metal remains.

S-0640


Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

OM-235281 Page 34

8-14. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not coverjoint formed by base metal.

S-0641


Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

Unsteady hand. Support hand on solid surface or use two hands.

8-15. Troubleshooting − Distortion

Distortion − contraction of weld metal during welding that forcesbase metal to move.

Base metal movesin the direction of

the weld bead.S-0642


Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

Notes

OM-235281 Page 35

8-16. Common GMAW (MIG) Shielding GasesThis is a general chart for common gases and where they are used. Many different combinations (mixtures) ofshielding gases have been developed over the years. The most commonly used shielding gases are listed in thefollowing table.

Application

GasSpray Arc Steel

Short CircuitingSteel

Spray ArcStainless Steel

Short CircuitingStainless Steel

Spray ArcAluminum

Short CircuitingAluminum

Argon All Positions5 All Positions

Argon + 1% O2Flat & Horizontal5

FilletFlat & Horizontal5

Fillet


FilletFlat & Horizontal5

Fillet


Fillet

Argon + 8% CO2Flat & Horizontal5

FilletAll Positions

Argon + 25%CO2

Flat & Horizontal1

FilletAll Positions All Positions4

Argon + 50%CO2

All Positions

CO2Flat & Horizontal1

FilletAll Positions

Helium All Positions2

Argon + Helium All Positions2

Tri-Mix4 All Positions

1 Globular Transfer2 Heavy Thicknesses3 Single Pass Welding Only4 90% HE + 7-1/2% AR + 2-1/2% CO2

5 Also for GMAW-P, All Positions

8-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause Remedy

Wire feed motor operates, butwire does not feed.

Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.

Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to matchwire size and type if necessary.

Wire spool brake pressure too high. Decrease brake pressure on wire spool.

Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip ifdamaged. Check size of contact tip and cable liner,replace if necessary.

Wire curling up in front of thewire feed rolls (bird nesting).

Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.

Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner lengthand diameter, replace if necessary.

Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gunend into housing just enough so it does not touch wirefeed rolls.

Dirty or damaged (kinked) liner. Replace liner.

OM-235281 Page 36

Problem RemedyProbable Cause

Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder.

Gas nozzle plugged. Clean or replace gas nozzle.

Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.

Restriction in gas line. Check gas hose between flowmeter and wire feeder, andgas hose in gun and cable assembly.

Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.

Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gassolenoid valve.

Incorrect primary voltage connected to welding powersource.

Check primary voltage and relink welding power sourcefor correct voltage.

Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worndrive rolls if necessary.

Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.

Incorrect voltage setting for selected wire feed speed onwelding power source.

Readjust welding parameters.

Loose connections at the gun weld cable or work cable. Check and tighten all connections.

Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.

OM-235281 Page 37

SECTION 9 − ELECTRICAL DIAGRAM

240 907-A

Figure 9-1. Circuit Diagram For Welding Power Source

OM-235281 Page 38

SECTION 10 − ACCESSORIES/CONSUMABLES

10-1. Accessories

Part No. Description Remarks

169598 M-25 Gun 15 ft (4.6 m) length/0.030-0.035 in. (0.8−0.9 mm) Wire Size

300349 DP 3545−20 Spool Gun Provides Excellent Feeding of Aluminum Wire

770589 Protective Cover Weatherproof Nylon

237702* Regulator/FlowmeterFor use with 100% CO2 Shielding Gas. Use with replacement

gas hose 144108.

*Available at Hobart/Miller welding distributors.

10-2. Consumables

Item Hobart Part No.* Miller Part No.**

Contact Tips

0.023/0.025 in. (0.6 mm) 770174 (5 per package) 087299 (10 per package)

0.030 in. (0.8 mm) 770177 (5 per package) 000067 (10 per package)



Nozzles

1/2 in. orf − flush 770544 200258

1/2 in. orf − 1/8 in. recess — — 169724

5/8 in. orf − 1/8 in. recess — — 169725

5/8 in. orf − flush 770405 169726

5/8 in. orf − 1/8 in. stickout — — 169727

Tip Adapter 770403 169728

Nozzle Adapter — — 169729

Replacement Liners

0.023/0.025 in. (0.6 mm) 196139 194010

0.030/0.035 in. (0.8/0.9 mm) 196139 194011

0.035/0.045 in. (0.9/1.2 mm) 196140 194012

Replacement Drive Roll

0.023/0.025 in. (0.6 mm) and 0.045 in. (1.2 mm) V GrooveAllows use of .024 in. Solid and 0.045 in. Solid and Flux Cored Wire 235287 235287

0.030 in. (0.8 mm) and 0.035 in. (0.9 mm) V GrooveAllows use of 0.030 in. and 0.035 in. Solid and Flux Cored Wire 235286 235286

0.035 in. (0.9 mm) VK GrooveV−Knurl Drive Roll for Hard Shell Cored Wires 132958 132958

0.045 in. (1.2 mm) VK GrooveV−Knurl Drive Roll for Hard Shell Cored Wires 132957 132957

*Available at farm and tool supply retailers.

**Available at Hobart/Miller welding distributors.


To maintain the factory original performance of your equipment, use only Manufacturer’s SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

Warranty Questions?

Call1-800-332-32817 AM − 5 PM EST

hobart_warr 2017-01

ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours.

SupportNeed fast answers to thetough welding questions?Contact your distributor orcall 1-800-332-3281. Theexpertise of the distributorand Hobart is there tohelp you, every step ofthe way.

AssistanceVisit the Hobart website:www.HobartWelders.com

Effective January 1, 20175/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a

serial number preface of MH or newer.

This limited warranty supersedes all previous Hobart warranties and is exclusive withno other guarantees or warranties expressed or implied.

Hobart products are serviced by Hobart or Miller Authorized Service Agencies.

LIMITED WARRANTY − Subject to the terms and conditionsbelow, Hobart Brothers Co. and Miller Electric Mfg. Co., Appleton,Wisconsin, warrants to its original retail purchaser that new Hobartequipment sold after the effective date of this limited warranty isfree of defects in material and workmanship at the time it is shippedby Hobart. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALLOTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDINGTHE WARRANTIES OF MERCHANTABILITY AND FITNESS.Within the warranty periods listed below, Hobart/Miller will repair orreplace any warranted parts or components that fail due to suchdefects in material or workmanship. Hobart/Miller must be notifiedin writing within thirty (30) days of such defect or failure, at whichtime Hobart/Miller will provide instructions on the warranty claimprocedures to be followed. If notification is submitted as an onlinewarranty claim, the claim must include a detailed description of thefault and the troubleshooting steps taken to identify failedcomponents and the cause of their failure.Hobart/Miller shall honor warranty claims on warranted equipmentlisted below in the event of such a failure within the warranty timeperiods. All warranty time periods start on the delivery date of theequipment to the original retail purchaser, and not to exceed twelvemonths after the equipment is shipped to a North Americandistributor or twelve months after the equipment is shipped to anInternational distributor.1. 5 Years — Parts and Labor

* Original Main Power Rectifiers only to include SCRs,diodes, and discrete rectifier modules

* Reactors* Stabilizers* Transformers

2. 3 Years — Parts and Labor* Drive Systems* Idle Module* PC Boards* Rotors, Stators and Brushes* Solenoid Valves* Spot Welder Transformer* Switches and Controls

3. 1 Year — Parts and Labor Unless Specified(90 days for industrial use)* Accessories* Batteries (Trek 180 Only)* Contactors* Field Options

(NOTE: Field options are covered for the remainingwarranty period of the product they are installed in, orfor a minimum of one year — whichever is greater.)

* Flowgauge and Flowmeter Regulators (No Labor)* HF Units* MIG Guns/TIG Torches* Motor-Driven Guns* Plasma Cutting Torches* Regulators* Relays* Remote Controls* Replacement Parts (No labor) − 90 days* Running Gear/Trailers* Water Cooling Systems* Spoolguns

4. 6 Months — Parts* Batteries

5. Engines and tires are warranted separately by themanufacturer.

Hobart’s 5/3/1 Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,cutting nozzles, contactors, brushes, relays, workstation table tops and welding curtains, or parts thatfail due to normal wear. (Exception: brushes andrelays are covered on all engine-driven products.)

2. Items furnished by Hobart/Miller, but manufactured byothers, such as engines or trade accessories. Theseitems are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other thanHobart/Miller, or equipment that has been improperlyinstalled, improperly operated or misused based uponindustry standards, or equipment which has not hadreasonable and necessary maintenance, or equipmentwhich has been used for operation outside of thespecifications for the equipment.

HOBART PRODUCTS ARE INTENDED FOR PURCHASE ANDUSE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONSTRAINED AND EXPERIENCED IN THE USE ANDMAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, theexclusive remedies shall be, at Hobart’s/Miller’s option: (1) repair;or (2) replacement; or, where authorized in writing by Hobart/Millerin appropriate cases, (3) the reasonable cost of repair orreplacement at an authorized Hobart/Miller service station; or (4)payment of or credit for the purchase price (less reasonabledepreciation based upon actual use) upon return of the goods atcustomer’s risk and expense. Hobart’s/Miller’s option of repair orreplacement will be F.O.B., Factory at Appleton, Wisconsin, orF.O.B. at a Hobart/Miller authorized service facility as determinedby Hobart/Miller. Therefore no compensation or reimbursement fortransportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIESPROVIDED HEREIN ARE THE SOLE AND EXCLUSIVEREMEDIES. IN NO EVENT SHALL HOBART/MILLER BE LIABLEFOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL ORCONSEQUENTIAL DAMAGES (INCLUDING LOSS OFPROFIT), WHETHER BASED ON CONTRACT, TORT OR ANYOTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN ANDANY IMPLIED WARRANTY, GUARANTY ORREPRESENTATION AS TO PERFORMANCE, AND ANYREMEDY FOR BREACH OF CONTRACT TORT OR ANYOTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDINGANY IMPLIED WARRANTY OF MERCHANTABILITY ORFITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TOANY AND ALL EQUIPMENT FURNISHED BY HOBART/MILLERIS EXCLUDED AND DISCLAIMED BY Hobart/Miller.

Some states in the U.S.A. do not allow limitations of how long animplied warranty lasts, or the exclusion of incidental, indirect,special or consequential damages, so the above limitation orexclusion may not apply to you. This warranty provides specificlegal rights, and other rights may be available, but may vary fromstate to state.

In Canada, legislation in some provinces provides for certainadditional warranties or remedies other than as stated herein, andto the extent that they may not be waived, the limitations andexclusions set out above may not apply. This Limited Warrantyprovides specific legal rights, and other rights may be available,but may vary from province to province.

Resources AvailableAlways provide Model Name and Serial/Style Number.

To locate a Service Center:Call 1-800-332-3281or visit our website at www.HobartWelders.com/wheretobuy

For Technical Assistance:Call 1-800-332-3281 7 AM to 5 PM EST − Monday through Friday

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2017 Hobart Brothers Co.. 2017-01

Hobart Brothers Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA

For Assistance:Call1-800-332-3281

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Owner’s Record

Thank you for purchasing Hobart. Our trained technical support team isdedicated to your satisfaction. For questions regarding performance, op-eration, or service, contact us!